STAMPER G.RAU GMBH & CO. KG Global metal specialists who have come to trust BRUDERER. WEISS-AUG CO. BRUDERER’s high-performance stamping technology has helped Weiss-Aug increase productivity. PREVIEW BLECHEXPO 2019 The ideal solution for every task. Three stamping lines in action. The magazine for high-performance stamping technology / 2019
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STAMPER - BRUDERER AG · Stepper has provided a multi-stage stamping tool for this purpose which can be used for high-precision production with a speed of up to 1,700 strokes per
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STAMPER
G.RAU GMBH & CO. KG
Global metal specialists who have come to trust BRUDERER.
WEISS-AUG CO.
BRUDERER’s high-performance stamping technology has helped Weiss-Aug increase productivity.
PREVIEW BLECHEXPO 2019
The ideal solution for every task. Three stamping lines in action.
The magazine for high-performance stamping technology / 2019
2 | STAMPER – 2019
BRUDERER stamping presses are made for complex
tasks. Come and see what we have to offer –
both in terms of new and retrofitted machines –
at Blechexpo in Stuttgart where we will have three
complete stamping solutions on display.
Precision matters.
precise
strong
durable
fast
STAMPER – 2019 | 3
high-performance tools for the most demanding clientele of
BRUDERER stamping presses.
hapema GmbH and Leicht Stanzautomation GmbH, who
are also headquartered in the Pforzheim area, are anoth-
er two innovative businesses in this sector. hapema is a
stamping company and developer of precision tools, and a
valued customer and partner to many international firms,
enjoying constant growth.
We then paid a visit to another global player and market
leader in hi-tech components for strip processing, namely
Leicht Stamping Automation – a reputed specialist for
peripheral systems in stamping and forming technology.
It never ceases to amaze me how much innovation comes
into play in order to optimise and constantly improve
processes in all areas.
And now you too can be amazed! BRUDERER, with a number
of trade fair partners, will have a presence at the forth-
coming Blechexpo, being held from 5–8 November 2019 in
Stuttgart. This year, we will be showing no fewer than three
complete stamping solutions at Blechexpo. Equipped
with precision tools by Mark, Stepper and hapema respec-
tively, they will be stamping components for a variety of
applications, from low speed to high speed. We would love
for you to pay us a visit, as there will be plenty to see and
to discover.
In the meantime, happy reading.
Kind regards,
Andreas Fischer
At the heart of stamping technology
In this, our latest edition of STAMPER, we are proud to
present a few select representatives of stamping and tool
technology and their peripheral equipment, located both
in the USA and at the heart of the German precision engi-
neering sector, namely Pforzheim. No other region is home
to as many precision engineering, tool-making, stamping
and forming companies. All five firms that we feature have
been our partners for many years now, and have come
to rely on the BSTA high-performance stamping presses –
read on to find out more about their experiences.
One of them is G.RAU GmbH & Co. KG – experts in the
production of strips, tubes and wires using precious metals,
special alloys and composite materials. The company was
founded in 1877 to supply the local jewellery industry, but has
constantly evolved and developed since then to become
one of the world’s leading specialists for metal solutions.
From there we journey overseas to our long-term US partner
Weiss-Aug Co.Inc. This company has developed an in-die
laser welding process for use in the manufacturing of high-
precision parts. After over 30 years and with countless
billions of precision parts produced on BRUDERER high-
performance stamping presses for the automotive and
medical technology industries, Weiss-Aug has fully
updated its machine inventory, and is pleased to report
on their initial experiences with their new equipment.
Back in Germany and just a few miles down the road from
G.RAU, we have a market leader in the manufacturing of
modular design high-precision tools for clients from around
the world. Founder Fritz Stepper made a name for himself
with the concept of progressive tools. His son Michael has
since taken over, with the company now providing perfect
Andreas Fischer,CEO
EDITORIAL
4 | STAMPER – 2019
THE RIGHT SOLUTION FOR EVERY APPLICATION.
BRUDERER at Blechexpo 2019:
Everyone involved in stamping technology knows
BRUDERER. Especially when it comes to high-speed
and high-performance stamping. With its comprehen-
sive range of products and technologies, BRUDERER
offers the perfect solution for almost any stamping
task. As such, the BRUDERER stand at this year’s
Blechexpo in Stuttgart will be well worth a visit.
From 5-8 November 2019, it will be trade fair time again.
The 14th Blechexpo, in conjunction with the 7th Schweisstec
fair, will be opening its doors in Stuttgart to expert visitors
and exhibitors. This year’s event has already generated a
great deal of interest, with the organisers registering more
exhibitors, more exhibition floor space and a greater inter-
national presence than in 2017. The numbers speak for
themselves, with no fewer than 150 more primary exhibitors
and a 20 % increase in exhibition floor space compared
with two years ago. It is looking very likely that the results
from the record-breaking year in 2017 will be topped, with
some 1,500 exhibitors across nine exhibition halls set to
greet visitors to Blechexpo/Schweisstec 2019.
Blechexpo 2019
Landesmesse Stuttgart
5. – 8.11.2019
BRUDERER: Hall 6, Stand 6308
www.blechexpo-messe.de
www.bruderer.com/en/expo/
BLECHEXPO (Germany, Stuttgart) 05.11. – 08.11.2019
FABTECH (USA, Chicago) 11.11. – 14.11.2019
BRUDERER in action.Three stamping lines – endless possibilities. See for yourselves at
Blechexpo.
STAMPER – 2019 | 5
2-in-1 solution for all speeds
At Blechexpo, BRUDERER will be exhibiting a complete
stamping line consisting of a BSTA 510-125B2 with BPG 22
planetary gear and a stamping tool made by the Austrian
toolmaker Mark Metallwarenfabrik GmbH. Thanks to its
clever BPG 22 gear technology, the BSTA can be run at high
stroke speeds in production mode as well as at low speeds
in test or BPG mode. With this system, which represents an
alternative to a servo drive, BRUDERER is the only manu-
facturer who offers a solution where stamping tools can be
tested at low stroke speeds directly on the production ma-
chine. Of course, parts can also be produced in BPG mode
at low speeds, and using the stroke speed modulation in
BPG mode, high productivity can be achieved even at those
low stroke speeds.
The technology behind this is a planetary gear directly
mounted on the main motor of the stamping press. It allows
the operator to run the press at the lowest stroke speeds
whilst using the maximum stamping force and full operating
capacity, all the while accurately controlled via a hand-held
control unit.
The values obtained in BPG mode can be transferred one-
to-one into normal production mode, resulting in increased
efficiency and a tangible gain in productivity, as a stamping
tool can be tested in BPG mode on the same stamping press
which is then subsequently used for high-speed production.
Visitors to the BRUDERER trade stand 6308 in hall 6 will be
able to see the benefits for themselves, with a stamping line
featuring a BSTA 510-125 with planetary gear as the centre
piece. Equipped with a precision stamping tool courtesy of
Mark, it will produce detent pins for the automotive industry
at 250 strokes per minute, set to a stroke length of 57 mm.
These deep-drawing parts are combined into subassemblies
at Mark and subsequently mounted into the shifting domes
of gearboxes.
The family-run company from Spital am Pyhrn in Austria is
a global leader in metal processing. BRUDERER stamping
presses produce perfect deep-drawn parts, making them an
automatic first choice for Mark. –›
BSTA 510-125B2 STAMPING LINE
IN FACTS AND FIGURES
Planetary gear BPG 22
Servo feed BSV 300
Feed length 27 mm
Stamping tool Mark Metallwarenfabrik GmbH
Stamped part Detent pin in deep-drawing
process
Stamping strip Strip thickness: 0.7 mm
Strip width: 30 mm
Strip material: steel strip DC 04
Speed max. 250 spm
Stroke height 57 mm
Output 250 parts/min.
Pallet winder NOXON Automation Gmbh +
Co. KG, PH 14-2T
OilingRaziol Zibulla & Sohn GmbH,
Benjamin 4.0 und LAMA 3000
Tool monitoring BRUDERER
Sound-proof cabin Fahrer AG
Location BRUDERER, Hall 6, Stand 6308
BSTA 510
Press force 510 kN
Tool loading area 950 – 1,500 mm
Speed max. 100 – 1,120 spm
Planetary gear BPG 22
Different models on request, subject to change.
6 | STAMPER – 2019
High speed – even higher precision
As a further highlight at the trade fair, BRUDERER will be
demonstrating a stamping line consisting of a high-speed
BSTA 200HS-60B2 with a precision stamping tool by Stepper.
Toolmaker Fritz Stepper GmbH & Co. KG from Pforzheim is a
long-time associate of BRUDERER and one of the first ports
of call for the high-volume, high-precision manufacture of
electronic connectors and contacts. The two firms will com-
bine to demonstrate what is possible today and in the future
in the field of ultra-high-speed stamping.
Stepper has provided a multi-stage stamping tool for
this purpose which can be used for high-precision
production with a speed of up to 1,700 strokes per min-
ute. For optimum operation of the stamping tool, the press
offers the function of adjusting the BDC ram position during
stamping in increments of µm, and further adjustments
of the ram position according to various criteria.
At this year’s Blechexpo, BRUDERER will be demonstrating the impressive range of machines and technologies that the company has to offer to meet the variety of needs of the stamping and forming sectors.
Original BRUDERER retrofit as used by
Leicht Stanzautomation
A third stamping line from BRUDERER can be seen in hall 6
at the trade fair stand 6208 of Leicht Stanzautomation GmbH,
namely a BSTA 80-97B2 retrofit with a modular progressive
tool by hapema GmbH and peripheral equipment by Leicht.
For over 30 years, the company hapema has stood for inno-
vative solutions in the field of stamping technology. hapema
provides a two-stage progressive tool made in 2008, on
which contact springs are produced at 600 strokes per
minute. The custom-designed contact riveting station is
protected by a utility model specification. Even after many
years in production, the stamping tool is still going strong
and meets the exacting quality requirements.
In short, this year’s Blechexpo is a great showcase for
the wide range of machines and technology which
BRUDERER offers for various applications in the stamping
and forming industry.
BSTA 80-97B2 RETROFIT STAMPING LINE
IN FACTS AND FIGURES
Servo feed BSV 300
Feed length 25 mm
Stamping tool hapema GmbH
Stamped part Contact spring
Stamping strip Strip thickness: 0.12 mm
Strip width: 35 mm
Strip material: 1.4301,
stainless steel
Speed max. 600 spm
Stroke height 32 mm
Output 1,200 parts/min.
Horizontal rewinding
technology
Leicht Stanzautomation GmbH,
PW-150-BA-90
Pallet winder Leicht Stanzautomation GmbH,
PWA-150
Raw strip welding
machine
Leicht Stanzautomation GmbH,
RSM-80-CNC
Spot welding machine Leicht Stanzautomation GmbH,
PSM-120
Oiling Microjet GmbH,
minimum lubrication
Tool monitoring BRUDERER
Sound-proof cabin Fahrer AG
Location Leicht Stanzautomation GmbH,
Hall 6, Stand 6208
BSTA 80-97B2 RETROFIT
Press force 800 kN
Tool loading area 970 mm
Speed max. 100 – 1,000 spm
Different models on request, subject to change.Example of a BRUDERER retrofit – a BSTA 50R-95 with B2 control and a BBV 202/120 roll feed.
www.g-rau.de
THE GLOBAL SPECIALIST FOR METALS RELIES ON BRUDERER.
STAMPER – 2019 | 9
Pforzheim with its famous jewellery and watch industry is known as the ‚Golden City‘. What’s less widely known, however, is that Pforzheim’s jewellery production paved the way for further international industries such as precision manufacturing and medical and stamping technology. The latter is the stomping ground for G.RAU GmbH & Co. KG, which like no other company is at home in the highly complex and versatile world of metals.
10 | STAMPER – 2019
In 1877, Gustav Rau founded his company for the
manufacture of pressings from gold and silver alloys
and thus became a supplier for the regional jewellery
industry. Shortly afterwards, with the introduction
of mechanical production, the company began to
flourish and expand. Today, G.RAU is a world-wide
supplier in the field of metal engineering and
acknowledged expert in the production of strips,
tubes and wires made of precious metals, special
alloys and composite materials. In addition,
G.RAU also uses these prematerials to manufacture
precision parts and entire complex assemblies. More
than 200 various kinds of metals and metal alloys
are processed and refined. ‘Metals are our world’
thus makes a fitting slogan for G.RAU. With its expert
knowledge, the company is a trailblazer in the field
of shape memory alloys, including special materials
such as Nitinol, a corrosion-resistant, high-strength
but nevertheless pseudoelastic nickel-titanium alloy.
Valued partner for many branches of industry
Thanks to this special focus, G.RAU has become the
preferred supplier to a variety of industry sectors. With
its three business segments – semi-finished industrial
products, parts & assemblies and semi-finished products
for the medical engineering industry –, G.RAU is a declared
partner of distinguished enterprises in the fields of auto-
motive supply, electrical engineering, measurement and
control technology, medical engineering and many other
sectors. Today, with around 650 employees, G.RAU is still
a family-owned metal engineering company with three
production sites in Pforzheim, one in Costa Rica and a
subsidiary in the United States.
G.RAU is also the parent company of several well-known
suppliers in the field of medical technology, such as the
two Pforzheim-based enterprises EUROFLEX GmbH and
ADMEDES GmbH. Both companies are global market lead-
ers in their respective product areas. Whereas EUROFLEX
predominantly supplies semi-finished products for implants,
such as wires, profiles or tubes, ADMEDES is specialised
in the manufacture of components made of Nitinol.
Currently, another five companies are part of the G.RAU
Group with around 1,480 employees in Germany, USA
and Costa Rica. With a group turnover of 196 million Euros –
of which 88 million generated by G.RAU in Pforzheim –
the company is now a global leader in metal solutions.
Expansion is the clear aim
This also explains the further strategic direction of the
company. Managing Director and owner Dr. Axel Pfrommer
has a clear vision: ”We will continue to focus on a wide
range of products and invest in expanding into new markets.
As a specialist for metals and metal alloys, however, we
will remain true to our strategic orientation and in addition,
focus more intensely on the field of surface engineering,
specifically on reel-to-reel electroplating.“ Here, the compa-
ny has set its sights mainly on stamped parts with special
surfaces, as they currently offer the best chances in the
marketplace and provide the greatest opportunity for value
creation. ”We know this particular business segment like the
back of our hands and can supply everything from a single
source,“ says Dr. Pfrommer. ”From the production of the Dr. Axel Pfrommer, Managing Partner G.RAU GmbH & Co. KG
STAMPER – 2019 | 11
strip through to stamping and surface finishing, everything is
done in house. For example, a metal strip for stamping can
be plated with 2µm silver on one side and 4µm silver on the
other side. For large quantities, this can result in enormous
cost savings.“
Complete control over all processes
The high precision required can only be achieved with state-
of-the-art technology. For this reason, G.RAU uses in-house
surface treatment processes in all three factories in Pforzheim.
”This allows us to keep an eye on all processes and deliver
first-class quality for all types of coating,“ assures Frank-Uwe
Hofmann, team leader at G.RAU. ”The same applies to stamp-
ing. All contact stamping-bending parts and assemblies are
produced on modern stamping and bending equipment made
by BRUDERER. ”We use copper, copper alloys, nickel, nickel
alloys, steel or stainless steel as well as compound materials
based on gold and silver for the contact surfaces. Following
this, our surface engineering department can electroplate or
chemically coat stamped strips and parts.“
From semi-finished products to assemblies
G.RAU offers a comprehensive range of products and
services in this business segment. Fully automated, they
can process several strips simultaneously into assemblies,
weld contact materials or rivet contacts, cut threads
or insert screws – and all this with a process-integrated
100 % vision control. A special product is the sliding contact
which the expert for metal solutions produces for the
automotive industry. It is used in the fuel tank encoder
system and is part of the fuel gauge. As there are different
types of petrol world-wide, the coating of the sliding contact
is matched to the fuel type used. ”Each sliding contact
must be within a tolerance of five-hundredths of a millimeter.
We have experimented with different stamping presses
and thus know that the series production of this part within
these tight tolerances is only possible on a high-perfor-
mance BRUDERER stamping press. On the BRUDERER stamp-
ing line, all parts are fully finished and ready for dispatch.“ –›
”Metals are our world.“
” We will continue to focus on a wide range of products and invest in expanding into new markets. As a spe-cialist for metals and metal alloys, however, we will remain true to our strategic orientation and in addition, focus more intensely on the field of surface engineering, specifically on reel-to-reel electroplating.“
Dr. Axel Pfrommer,
Managing Partner G.RAU
12 | STAMPER – 2019
Stamping team G.RAU.
An eye for perfection: tool making at G.RAU.
STAMPER – 2019 | 13
Precision in large-scale production
On 32,000 m2 production space, G.RAU produces more
than a billion stamped parts per year. ”Developments show
that we are on the right track with our claim for precision,“
states Dr. Axel Pfrommer. ”In our core markets, the trend
towards even tighter tolerances will continue in the next
few years. If a company can keep pace and deliver the best
values, it will stay at the cutting edge well into the future.
Therefore for stamped parts, we will continue to rely on
14 BSTA high-performance stamping presses in the range
of 20 to 80 tons are in operation at Pforzheim. They process
all types of steel, thermostatic bimetal, non-ferrous metal
and alloy strips with widths of up to 120 mm and thicknesses
from 60 µm to 5 mm.
Even stamping tools are produced in-house
The use of perfect stamping tools is vital for G.RAU in order
to guarantee their customers the accuracy of the parts
in series production. Thus it is no surprise that they have
an in-house tooling department which produces stamping
tools exclusively for internal use. Only in exceptional
circumstances are additional stamping tools bought in. With
their 40 members of staff, including six design engineers
specialised in tool making, G.RAU are able to manufacture
nearly all tool types themselves – a key advantage for their
stamping business.
Achim Regelmann, Manager of the Division Parts & Assem-
blies at G.RAU, is convinced that ”the synergies between
stamping technology, deep drawing and extrusion lead
to optimum tooling solutions for our clients. Our in-house
surface engineering processes – such as electroplating,
chemical coating or vibratory finishing, i.e. deburring – give
us a clear competitive advantage.“
Customers appreciate experience and flexibility
According to Managing Director Dr. Pfrommer, the compet-
itive advantage is not only due to the precision for which
G.RAU is known, but also to the high degree of flexibility
when developing innovative products for their customers.
”Our expertise, which allows us to recommend and test new
materials for specific applications and thus develop and
produce unique products together with our customers, is a
clear USP of G.RAU.“
As a reliable and competent partner, the company supports
its customers in the complete material and process devel-
opment process. G.RAU are able to make this promise as
they have all the necessary departments and facilities in-
house, from consulting, conceptual design and developing
the samples to serial production. The development depart-
ment has its own chemical and physics lab with a scanning
electron microscope and several other testing systems. In
the design department, high-performance tool concepts
are developed using state-of-the-art 3D CAD systems and
simulation programmes, and finalised in collaboration with
the production and quality management department. These
product development efforts, in combination with the
experience of in-house tool manufacturing capabilities and
project management, ensure professional assistance and
advisory services even for complex projects.
Outstanding quality offers peace of mind
The current certifications in accordance with ISO 9001:2015,
IATF 16949:2016 and ISO 13485:2016 clearly demonstrate
that G.RAU puts special emphasis on compliance with all
required standards as well as the continuous development
and improvement of all business processes. This also applies
to the topic of sustainability. Environmentally-friendly materi-
als, energy-efficient components and the latest technology
are taken into consideration for all projects as an integral
part of the process. Thus G.RAU is also certified to ISO
14001:2015 and ISO 50001:2011, which is greatly appreciat-
ed by many customers and forms the basis of the high level
of confidence that customers have placed in G.RAU.
” A metal strip for stamping can be plated with 2µm silver on one side and 4µm silver on the other side. For large quantities, this can result in enormous cost savings.“
Dr. Axel Pfrommer
www.weiss-aug.com
PUSHING FOR PERFECTION.
BRUDERER helps Weiss-Aug New Jersey with advanced stamping technology to be more productive.
By Lincoln Brunner
STAMPER – 2019 | 15
In 2015, Weiss-Aug Co. located in East Hanover, New Jersey, noticed a recurring problem that they knew needed fixing, and fast. Their stamping dies, that were running in their 30+ year old BRUDERER presses – the old workhorses of their high-volume, high-precision stamping opera-tion – were starting to show excessive wear. The company’s engineers knew the root cause wasn’t tooling. Good as they were, the old single-crank mechanical presses were showing the inevitable marks of time and, as it turned out, were the root cause for exces-sive die wear.
16 | STAMPER – 2019
Mr. Alois J. Rupp, BRUDERER MACHINERY INC., CEOMr. Jeff Cole, Weiss-Aug Co., Inc., Vice President of OperationsMr. Dieter Weissenrieder, Weiss-Aug Co., Inc., PresidentMrs. Elisabeth Weissenrieder-Bennis, Weiss-Aug Co., Inc., Executive Vice PresidentMr. Mark Weissenrieder, Weiss-Aug Co., Inc., IT/Automation Manager
Other companies may not have raised the red
flag right away. But with millions of parts being
produced by every machine, every week and
customers regularly demanding zero-PPM defects,
the decision-makers at Weiss-Aug had to decide:
Do we refurbish the existing machines or invest
in new machinery at a premium cost of about
30 percent?
After a good bit of back-and-forth, Weiss-Aug Owner and
Founder Dieter Weissenrieder decided to bet big on nine
new BRUDERER BSTA 200 presses. The machines can
stamp at a rate of up to 2,000 strokes per minute, ideal for
the high-volume, intricate stampings – think connectors
for electronics – that Weiss-Aug provides for its customers
in the automotive, medical, interconnect, defense and
aerospace industries.
”This is not a machine that is used to stamp boat anchors,“
says Dieter Weissenrieder. ”This is a state-of-the-art machine
and is the perfect machine for the sophisticated products
that we produce. It is the favored high speed punch press
for our type of industry.“
Not that the 20-ton BRUDERERS – most of which Weiss-Aug
purchased in the 1980s – were high precision state-of-
the-art machines at that time, but BRUDERER has made
significant improvements in 30 years. Incredibly, some of
those machines had accumulated 80,000 to 90,000 production
hours and were still being used in regular production.
In fact, part of the internal struggle at Weiss-Aug arose
because the older machines were still humming along at
high speeds, albeit not at the level of consistency that the
company needs to maintain its quality standards.
After all the discussion, in-house and with BRUDERER,
Weiss-Aug chose new machinery over refurbished because
making that jump enabled them to increase their production
output by improving die life while moving ahead with the
technological advances that BRUDERER offered.
STAMPER – 2019 | 17
”In some cases, we will rebuild our machines as it makes
sense for certain products to do so“ Rupp says. ”In this
particular case… we knew it wasn’t a good decision for
him to do that.“
Weiss-Aug produces small, highly complex stamped parts
that are rarely flat. Most parts are coined, formed and bent
multiple times. The tolerances are extremely tight, many
times down to ± 0.01 mm.
Parts are stamped in quantities of many millions. This
kind of consistency cannot be expected from presses that
have 80,000 to 90,000 production hours ”on their back“.
Because of zero defect requirements in today’s environ-
ment, consistency from the first part to the last part is
mandatory. –›
”At the end of the day, these presses were old,“ says
Weiss-Aug Vice President of Operations Jeff Cole, who
Weissenrieder says lobbied the hardest for the new
presses. ”We were seeing premature tooling wear, and
we were seeing inconsistency in part geometry. So, we
realized that it was time to change.“
”In our case, we made the decision that, economically, it
didn’t make any sense to rebuild these 20-ton machines.
BRUDERER had incorporated significant technological
advances in these new machines, and now that these
machines are in production, the improvements in output
and part consistency are astonishing.
BRUDERER Machinery Inc. President Alois J. Rupp says
that even though he can maintain accuracy on rebuilt
presses, the older machines can’t accommodate the
new features that set newer technology apart. For that
reason and others, the reconditioned machines didn’t
make sense for Weiss-Aug.
” We got way ahead of our competitors in the space.“
Alois J. Rupp, CEO
BRUDERER MACHINERY INC.
18 | STAMPER – 2019
Zero defect – parts in perfection.
Designed to last – BRUDERER high-performance presses.
”When we were running the same dies making the same
parts in the new BRUDERER presses, we couldn’t believe
the improved consistency within production runs. Not only
were we able to increase press speeds, but most of all the
new machines reduced die maintenance. Dies also had to
be adjusted less frequently, reducing downtime. In summary,
productivity went up significantly,“ Cole states.
As a contract stamper, specializing in small, intricate and
high volume parts, Weiss-Aug uses many different types
of materials. Material types range from Be Cu, Phosphor
Bronze, Nickel, Stainless Steel and many exotic alloys.
Because of the competitive nature of manufacturing highly
complex parts at high volumes, Weiss-Aug runs its presses
at very high speeds. The design and construction of the
BRUDERER presses allows that. Weiss-Aug runs many of
their 20-ton BRUDERER presses at speeds of up to 1,700
strokes/minute. Cole states ”BRUDERER presses are ideal for
this kind of manufacturing.“
Because of the incredibly accurate construction of the
machines, Cole states ”consistence in manufacturing small,
intricate parts is assured. Today customers require zero
defect over millions of parts – something unheard of
20–30 years ago.” He states, that in today’s environment,
he needs highly precise tooling, flawless material and excel-
lent punch presses. He calls this the ”three legged stool“. If
one leg is missing, the entire process falls apart.
Designed to Last
Rupp says that his presses’ consistency originates with one
key feature of his company’s presses: the mass counterbal-
ance system that distributes the press’s forces more evenly
throughout the machine, thereby maintaining the press’s
stability at high speeds. The counterbalance system, which
Egon Bruderer patented more than 60 years ago, represents
a unique technology that the company still prides itself in.
”We didn’t realize it at the time, but it was a quantum leap,“
says Rupp, whose company is based in Ridgefield, N.J., a
30-minute drive from Weiss-Aug. ”We got way ahead of our
competitors in the space. And to this day, the technology
has come up, but it’s still not there yet. No one offers the
same engineering principles that we do.“
”Our customers, they know. They run different machines.
They know where they need the BRUDERER, and they know
where they can get away with another brand.“
Weissenrieder confirms that the reason for having bought
BRUDERER presses for the past 45 years is ”the latest
technology incorporated in the design of the presses and its
robust and accurate construction. The machines also retain
their value over many years.“
STAMPER – 2019 | 19
Faster Setups, With Less Variation
One of the improvements of BRUDERER’s new presses that
surpasses its predecessors is the servo feeding system
featured on the BSTA 200s.
At first, BRUDERER delivered the new presses to Weiss-Aug
with mechanical feed systems. However, Weiss-Aug quickly
determined that they wanted the servos instead – a
decision that simultaneously increased setup speeds and
decreased the person-to-person variability inherent in set-
ups determined by operators’ judgment rather than a servo
drive’s control system.
”Set up time is faster, almost 50 %“ Cole says. ”The setup
of a servo feed is very much automatic and foolproof.
The parameters, that is stroke, pitch and pilot release which
in the past were set manually, are now keyed in at the
initial set up and then retained in the ‘press library’. Not
only does this cut set up time, but guarantees consistent
set ups by eliminating personal preferences.“
Technology: Worth the Investment
If anyone can appreciate the value of Weiss-Aug’s invest-
ment in technology, it’s Cole. The stamping industry veteran
joined the company 25 years ago and has watched its
commitment to technology increase steadily over that time.
”Dieter has always been very supportive of buying the best
technology,“ Cole says. ”My plan is to continue to upgrade
to new technology as we move forward.“
In essence, the 200s give people, like Cole, incentive to
continue the good fight of meeting zero-defect demands
from customers who are also constantly asking for cheaper
parts prices.
”The challenge, the tight tolerances, the parts that no one
else wants to make,“ Cole says when asked what really
excites him. ”It’s very satisfying as you stand in the press-
room and watch those parts come off the press – all the
brainpower that went into figuring out the tooling and
making it all work.“ –›
20 | STAMPER – 2019
Technological investments offer the additional benefits of
attracting new talent to the company. Cole says finding
talent represents his biggest challenge today and having a
company with the latest and best equipment money can
buy including a great working environment gives him a
chance to attract quality people.
Mutual Respect
The Weiss-Aug story follows a typical script, they have been
BRUDERERS devotees for 45 years. In fact, the company
has over 31 BRUDERER presses running in its 3 press rooms
in New Jersey and its new plant in Apodaca, Mexico.
”He knows the business,“ Cole says of his boss. ”That’s why
when I go to him to talk about capital investment, he knows
what I’m talking about. He understands the business.
He knows we need precision equipment, cutting edge tooling
and talented team members to be successful.“
In that regard, BRUDERER considers Weiss-Aug one of its
model customers – not just because they buy so many
presses, but because the level of understanding the two
companies share.
”We are focused on high precision, high volume,“ Rupp says.
”Those are the two things that match with our products.
Weiss-Aug is a perfect customer. They understand quality.“
”The important thing with Weiss-Aug and with all of our good
customers, it’s about a mutual benefit,“ Rupp adds. ”That’s
where we do well with our customers. It has to be, or else
it’s a one-time sale or a short-lived relationship.“
” We are focused on high precision, high volume,“ Rupp says. ”Those are the two things that match with our products. Weiss-Aug is a perfect customer. They understand quality.“
STAMPER – 2019 | 21
Close to BRUDERER USA, in terms of location as well as quality and service.
22 | STAMPER – 2019
www.stepper.de
Always one step ahead, together with BRUDERER high
performance stamping presses.
NEXT STEPS BY STEPPER.
STAMPER – 2019 | 23
With the customer every step of the way. Toolmaking has changed fundamentally over the past decades. Lead times, project times and the complexity of modern stamp-ing tools are becoming more and more ambitious. One who paves the way and is a pioneer in the adoption of new technol-ogy is Stepper. As the global market leader in toolmaking, the industry leader from Pforz heim regularly scales new heights.
24 | STAMPER – 2019
The F1 Supertec stamping tool – combining the ultimate in precision and productivity.
STAMPER – 2019 | 25
Imagine back in 1976, a stamping tool is clamped down on
a BRUDERER high performance stamping press and taken
into operation. The machine runs in three-shift operation
at just under 1,000 strokes per minute. Together, the duo
of stamping tool and press, toiling away continuously, will
have produced 30 billion parts by today. Notably with the
same stamping tool, on the same stamping press. This
may sound like science fiction, but is in reality the result
of the successful collaboration of two market leaders in
their respective areas: BRUDERER and Stepper. A visit to
Stepper in Pforzheim shows how stamping tools and com-
plex components are made and what the advantages are
of perfection down to the smallest detail.
Fritz Stepper, the founder of the company, revolutionised
traditional toolmaking in the mid-sixties through modu-
lar technology, which over many decades has given the
company a leading edge. His ingenious idea was based
on individual modules taking on different tasks, such as
stamping, bending or embossing, or indeed carrying out
a combination of different tasks. The possibilities, i.e. the
number of production operations, are only limited by the
size of the tool loading area. –›
” We have recognised early on that we can be considerably more successful when seeking solutions with specialists in their area, than on our own and our partnership with BRUDERER started in the seventies and has been a real benefit for both of us.“
Michael Stepper, owner and CEO of
Fritz Stepper GmbH & Co. KG
26 | STAMPER – 2019
Rethinking processes to optimise working production methods.
Innovations in surface quality.
STAMPER – 2019 | 27
By using different modules, various parts can be manufac-
tured on the same stamping tool. A further advantage: the
module change is completed within a few seconds. This
inventive spirit, combined with decades of experience, is
the reason for Stepper’s outstanding reputation world-
wide. Development and training are thus important topics
within Stepper’s company structure. ”On the development
front, we don’t restrict ourselves to our own team. We reg-
ularly have development teams of our business associates
on site and together search for improvements and new
solutions. Our research is supported by various universi-
ties, such as the Pforzheim University of Applied Sciences,
and institutes as well as companies such as BRUDERER.
Thus in the course of time we have developed the ability
to further develop solutions which have worked in an ex-
perimental setup at a university or research institute and
bring those projects to industrial production stage.” Step-
per also shows above-average commitment for the train-
ing of young professionals. The toolmaker has around 200
employees, of which nearly 40 are apprentices in training.
This is a substantial proportion not just for this sector, but
across all industries. The apprenticeships on offer include
the professions of Precision Mechanic, Technical Product
Designer and Stamping and Forming Mechanic.
This combined expertise leads to solutions which set Step-
per apart from its competitors world-wide. One of their
main distinguishing features is the special surface coating
technology which Stepper uses for their tools. ”With the
Stepper diamond coating, parts can be manufactured in
larger numbers, in a shorter time and with less tooling
wear than with conventional carbide tools,“ explains
Michael Stepper. ”The natural hardness of the carbide
at 1,500 HV is not sufficient for a long tool service life.
Therefore, using our own equipment, we have developed
special coatings which allow us to increase the surface
hardness by a factor of three. With this coating, in an ideal
case we can improve the service life of a stamping tool
tenfold. In order to make sure that we have the optimum
coating for every application, we are fully conversant with
all relevant technologies, such as physical vapour depo-
sition (PVD), chemical vapour deposition (CVD) or plasma
laser deposition (PLD).“ –›
That's why Stepper's motto is: the new dimension of stamping technology.
Raimund Ochs, Director and Board Member at Fritz Stepper GmbH & Co. KG
28 | STAMPER – 2019
”Over 90 percent of our orders relate to the contact parts
business,“ he adds. This includes the core segments auto-
motive and medical technology, but also white and brown
goods, from shavers and washing machines through to
mobile phones and computers. ”The field of applications
is broad and the requirements are becoming increasingly
complex. Particularly in the automotive contacts business.“
Desiring to combine several processing steps with differ-
ent materials in one operation, Stepper developped their
modular tools into combined stamping tools for single-stage
processing. ”This greatly reduces production times, and ex-
pensive storage costs can be avoided,“ Stepper expounds.
”The three or four-stage production, which includes the
forming and assembly of three materials or components, is
one of the showpieces of our technology. Where different
variants of a part need to be produced, of course the mod-
ular design comes into its own. We have tools which can
be used for up to 30 different variants of a component. The
increasing miniaturisation is only one of many challenges
we still face.“
The smaller the contacts, the more complex the forming
and the more elaborate the assembly of components per
stamping operation, the bigger is the requirement for length
of tool and tool loading area in the stamping press. BRUDER-
ER has recognised this and has extended the bed length for
various models of their BSTA series.
”The length of the tool loading area is now more than
double that of our earlier BRUDERER stamping presses.
For many applications, a tool loading area of, for example,
1,100 mm is no longer sufficient,“ Stepper says. ”Therefore
we now have BRUDERER presses with bed lengths of up to
1,800 mm and, for example, at BSTA 510 with 1,250 mm tool
loading area“.
As Stepper is known for their expertise in coating and prod-
uct development, the toolmaker receives enquiries from
around the world for problems which no other company
would be able to solve. Stepping up to the plate, some time
ago Stepper was able to develop a stamping tool for a four-
part component which had to withstand centrifugal forces
of up to 85 G when in use. ”No other manufacturer dared to
take this on,“ remembers Michael Stepper. ”Although the
customer conducted tests successfully, no manufacturer
would commit to serial production. Until he contacted us,“
he adds with a smile. Within a few months, thanks to hard
work and dedication, a stamping tool was developed which
not only fulfilled all the requirements, but was also able to
deliver the requested quantities of parts to be produced.
”The stamping tool consists of 5,000 individual parts and
is a true masterpiece. It shows what we understand by F1
Supertec: the best available material, in this case the alloy
out of which the tool is made, in connection with the best
technologies for manufacturing the stamping tool. And last
but not least a seamless control. Using our own scanning
electron microscope, we can inspect the result with
a 100,000-fold magnification down to one hundredth µm.“
That is reason enough for many customers to not only order
a stamping tool from Stepper, but also to contract out the
production of certain components to the toolmaker. ”For re-
ally complex jobs, it gives the customer peace of mind to re-
ceive precision parts from the word go. We either take over
production of the whole lot, or our stamping room provides
the initial batches until the customer’s own production is
up and running reliably. This is of course also in our interest
as with our own stamping room we have the possibility to
thoroughly test new materials and new solutions in-house. If
it needs be, for a whole year or until we can be certain we’re
ready to introduce a new development to the market.“
The latest highlights from Stepper and its associate BRUDERER
will be on show from 5th to 8th November 2019 at Blech-
expo in Stuttgart, on the BRUDERER stand 6308 in hall 6.
Following the motto ”The ultimate in availability through
state-of-the-art technology“, BRUDERER and Stepper are go-
ing to demonstrate at the international trade fair in Germany
what is already possible today using an ideal combination of
high-performance stamping press and precision stamping
tool.
STAMPER – 2019 | 29
Desiring to combine several processing steps with different materials in one operation, Stepper developped their modular tools into combined stamping tools for single-stage processing. ”This greatly reduces production times, and expensive storage costs can be avoided.“
A one-stop shop from tool making through to the high-volume production of stamped parts.
www.stanzautomation.de
www.hapema-gmbh.de
With BRUDERER retrofitted automatic stamping presses.
INCREASING VALUE CREATION.
Example of a BRUDERER retrofit - a BSTA 50R-95 with B2 control and a BBV 202/120 roll feed.
STAMPER – 2019 | 31
The changing economic climate is leading to many businesses having to review their cost structures and their investments in means of production. With its retrofit solutions, BRUDERER provides an interesting alternative. Here we present two businesses who are making the most of this retrofit proposition.
With various trade conflicts on the boil and the endless
Brexit negotiations, the global economy is going through
a period of turbulence at the moment that is doing nothing
to calm the economic climate. Many businesses are not
managing to generate growth at present, while markets
continue to become more global – as does the competition.
Companies are being confronted with significant fluctu-
ations in order intake and a price dynamic which is influ-
enced by the presence of a variety of other suppliers. The
only way for stamping and tooling firms to be successful in
the face of increasing competition is to further develop their
own competencies while at the same time improving their
cost efficiency.
This is where BRUDERER with its high-performance stamping
presses has been able to provide an attractive proposition for
a number of years now when it comes to increasing the value
creation potential of investment in stamping technology. The
magic word is retrofitting, or the comprehensive revision of
older BRUDERER automatic stamping presses. Many firms
are extolling the virtues of overhauling BRUDERER machines,
but a genuine retrofit with a complete mechanical and
electrical revision with original parts and quality can only
be provided by BRUDERER. Furthermore, customers have
the choice of having their own BRUDERER presses over-
hauled by BRUDERER, or acquiring a used model that has
been modernised.
”A retrofitted original BRUDERER high-performance stamping
press has the very latest technology both mechanically and
in terms of controlling,“ explains BRUDERER CEO Andreas
Fischer. ”Additionally, the mechanical feed can be replaced
by servo feed during the revision. Furthermore, today’s
PhotographyJERRY GROSS FOTOSTUDIO AGImages courtesy of our partners
PRINTSchmid-Fehr AG
Edition 7,000
LanguagesGerman, English, French, Italian, Chinese
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